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DUALSUN SPRING Installation, Use & Maintenance Manual

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English
Installation, use, maintenance
manual DualSun SPRING
v1.21
2023

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Summary of Contents for DUALSUN SPRING

  • Page 1 English Installation, use, maintenance manual DualSun SPRING v1.21 2023...

  • Page 2: Table Of Contents

    4. Electrical Installation ........................25 4.1. Electrical connection ......................25 4.2. Position of the micro inverter for the FLASH 425 and the SPRING 425 ........ 26 4.3. Electrical fittings, cables and diodes .................. 27 4.4. Grounding and lightning protection ..................28 4.5.
  • Page 3 8.1. Guarantee conditions ....................... 54 8.2. Disclaimer ........................54 9. Technical appendices ........................55 9.1. SPRING hydraulic pressure losses ..................55 9.2. SPRING thermal power ....................57 9.3. SPRING thermal behavior ....................60 9.4. Sizing and adjusting the DualSun filling vessel ..............64...

  • Page 4: Introduction

    Please read this installation manual thoroughly and in detail in order to be able to fully exploit the functionality of the product. DualSun disclaims all liability for defetcs and damages that would result from non-compliance with the installation instructions (improper use, incorrect installation, handling error, etc.).

  • Page 5: Solar Thermal Standards

    The installation instructions and safety instructions must be met. Observe the regulations on the prevention of industrial accidents prescribed by professional associations, in particular those relating to work carried out on the roof. 1.3. Solar thermal standards FLASH and SPRING DualSun panels must be recycled...

  • Page 6: General Description

    • They produce much more heat (80%) than electricity (20%) when exposed to the sun, • Their yield decreases when their temperature increases. The SPRING panel thus absorbs solar energy to restore it in the form of two energies useful for the operation of buildings: •...

  • Page 7: Technical Characteristics Of The Dualsun Spring Panel

    2. Heat exchanger : fully integrated into the panel, it allows excellent heat transfer between the photovoltaic front panel and the circulation of water. For more details on the DualSun SPRING panel, you can consult the following chapters of the Installation, use,...

  • Page 8: Recommended Hydraulic Flow Rates For The Dualsun Spring Panel

    This property also causes a slight drop in pressure. Membrane effect: The thermal inertia difference between the DualSun heat exchanger and the heat transfer fluid causes pressure variations according to temperature variations. Due to its relative flexibility, the DualSun heat exchanger can expand or contract.

  • Page 9: Maximum Allowable Pressures For The Dualsun Spring Panel

    When filling the hydraulic circuit, a flow rate increase implies a pressure increase. 2.1.3. Maximum allowable pressures for the DualSun SPRING panel CAUTION It is imperative never to exceed the following pressures in DualSun panels: Maximum operating pressure = 1,5 bar Maximum filling pressure = 2 bar The maximum filling pressure corresponds to the allowable pressure in the panels, to purge correctly the air during hydraulic commissioning.

  • Page 10: General Recommendations

    SPRING panel. 2.2. General recommendations 2.2.1. Handling DualSun modules should be handled like any glass product. To avoid accidents, injuries, or damage to the module during work, the following precautions must always be observed: • Do not step on the modules.

  • Page 11: Technical Considerations

    DualSun suggests installing the modules in areas where the temperatures are between -20 ° C and + 50 ° C, which corresponds to the minimum and maximum monthly average temperatures, in accordance with IEC 60364-5-51.

  • Page 12: Types Of Mounting

    2.3.6. Protection against fire / explosion Do not install the DualSun modules in the vicinity of highly flammable gases, vapours, or dust (e.g., next to a gas station or containers). The national and local fire prevention standards and regulations must be respected during installation.

  • Page 13: Mechanical Installation

    Artificially concentrated solar radiation must not be directed onto the module. The frame thickness and the dimensions of the SPRING panel are identical to photovoltaic panels. It adapts easily to photovoltaic mounting systems; however, it is necessary to ensure the positioning of the hoses in relation to the mounting system frame and to the roof covering surface.
  • Page 14 - Overlap in depth of the clamps on the frame: between 7mm and 12 mm - Minimum clamps width: 50mm. - Minimum Clamps thickness: 3mm Installers must ensure that the resistance of the clamps is sufficient given the maximum pressure to which the module can be exposed. The clamps are not supplied by DualSun.

  • Page 15: Assembly Specifications

    3.2.1. Installation areas on the rails of the mounting system DualSun panels are certified for a maximum load of 5400 Pa positive (snow) and -2400 Pa negative (wind) in a standard configuration with four clamps. For the details of the loads according to the installation modes, please consult the table below.
  • Page 16 Installation, use, maintenance manual DualSun SPRING Panels : DSTNxxxM12-B320SBB7 ; DSTIxxxM12-B320SBB 7 Installation 4 clamps on the long side 4 clamps on the short side method Installation Position of 330<S<430 0 < H < 300 clamps Maximum certi- 6600Pa positive, 3600Pa negative...
  • Page 17 19 mm between the roof and the micro-inverter or optimizer and of 13 mm between the back of the SPRING module and the top of the microinverter or optimizer. See assembly example below:...

  • Page 18: Raising The Spring Panels Relative To The Roof

    SPRING 425 SPRING 375 and previous CAUTION The bulk of the hydraulic fittings on the rear side of the DualSun SPRING panels is to be considered carefully to avoid contact of the fittings with the surface of the roof cover.

  • Page 19: Possible Laying Configurations With Hydraulic Connections

    3.2.4. Possible laying configurations with hydraulic connections To facilitate their routing in a maximum of configurations, the DualSun hydraulic connections have been devel- oped to allow a connection in portrait or landscape mode, it is thus possible to adapt the hydraulic connections...
  • Page 20 Installation, use, maintenance manual DualSun SPRING Laying configuration 2 Installation configuration 1 Portrait panel / Landscape link Portrait panel / Portrait link Installation configuration 4 Installation configuration 3 Landscape panel / Landscape link Landscape panel / Portrait link Thus, the hydraulic connections can be oriented so as to avoid the rails of the mounting system or to adapt to...

  • Page 21: Installation Of Spring Panels On A Trapezoidal Sheet Metal Roof

    Installation, use, maintenance manual DualSun SPRING NOTE Claws to be fixed on the frame return of the SPRING panels to keep the hydraulic hoses as close as possible to the frame are available in the DualSun inlet / outlet fittings kit.
  • Page 22 The positioning of the first module depends on the corrugation crest routing detailed above. Then check that each DualSun fitting is correctly positioned in the corrugation recess, according to the width of the inter-panel clamps, respecting the minimum distances for the routing of the hydraulic links through the corrugation crests.
  • Page 23 • The height between the rails and the roof surface is greater than the external diameter of the flexible hoses indicated in chapterRaising the SPRING panels relative to the roof [18] • The bending radius of the flexible hose is greater than the minimum bending radius to avoid the rails,...
  • Page 24 A, B and C in chapter Installation areas on the rails of the mounting system, to respect the minimum bending radius (Rc ) of the mini hydraulic hoses, see chapter Raising the SPRING panels relative to the roof [18].

  • Page 25: Electrical Installation

    Installation, use, maintenance manual DualSun SPRING 4. Electrical Installation Electrical connection [25] Electrical fittings, cables and diodes [27] Grounding and lightning protection [28] Indirect lightning strike [28] 4.1. Electrical connection The nominal electrical parameters Icc, Vco and Pmax of the modules are determined under standard test conditions STC (standard testing condition): illumination of 1000 W/m²...

  • Page 26: Position Of The Micro Inverter For The Flash 425 And The Spring 425

    WARNING If additional PV modules must be installed in string with DualSun modules, their power and current must be equal to those of DualSun panels within the limits of manufacturers' tolerances 2. Wiring in parallel For DualSun modules connected in parallel, a corresponding overcurrent protection must be used.

  • Page 27: Electrical Fittings, Cables And Diodes

    Never open the junction box The junction box of the DualSun module contains bypass diodes which are in parallel connection with the cell wires. If a hot spot occurs locally on one or more cells, the diode will enter into service to prevent the main current from flowing through the hot cells in order to limit overheating and loss of performance of the module.

  • Page 28: Grounding And Lightning Protection

    It is imperative to refer to the local regulations in force to comply with specific requirements DualSun modules must be grounded with prongs, lugs or other suitable means. Grounding can be done through the holes made for this purpose as part of each module.
  • Page 29 Installation, use, maintenance manual DualSun SPRING electrical cable loops must be avoided and the surface between the cables must be as small as possible, as can be seen in the graph below:...

  • Page 30: Hydraulic Installation

    Installation of DualQuickfit links [36] 5.1.1. Inter-panel connection - DualQuickfit links To connect SPRING panels to each other, DualSun has developed DualQuickfit quick couplings, mounted on flexible lines packaged in the form of crowns. These flexible lines are pre-assembled with a flexible DN15 or DN26 hose, depending on the nominal flow rate required, see table below, and with DualQuickfit quick couplings, portrait or landscape, depending on the layout of the installation.

  • Page 31: Maximum Number Of Panels Per Hydraulic Line

    Installation, use, maintenance manual DualSun SPRING - Inter-coupling distance of the hydraulic links: Portrait Landscape DN15 DN26 DN15 DN26 xxxM-60-3BBPN SPRING 300: 1062 SPRING 300: 1062 1710 mm xxxM-60-3BBPI DSTNxxxG1-360SBB5 SPRING 375 SPRING 375 SPRING 375 SHINGLE: 1210 SHINGLE: 1210...

  • Page 32: Panel Field Inlet / Outlet Fitting

    Installation, use, maintenance manual DualSun SPRING 5.1.3. Panel field inlet / outlet fitting 1. Pressurized system A kit of brass inlet / outlet fittings is used to connect the inter-panel links to the transfer circuit. • M3 / 4 '' for DN15 inter-panel links •...
  • Page 33 Installation, use, maintenance manual DualSun SPRING WARNING Tightening of screw caps = 4 Nm maximum The inlet / outlet fitting kit is to be installed as specified below:...
  • Page 34 Installation, use, maintenance manual DualSun SPRING Simplified diagram installation of a hydraulic line with 4 panels in portrait Simplified diagram installation of a hydraulic line of 2 panels in landscape 1. Hydraulic inlet 2. Hydraulic outlet 3. DualQuickfit / Transfer circuit connection...
  • Page 35 Installation, use, maintenance manual DualSun SPRING CAUTION The fluid must flow from bottom to top in the panels Respect the hydraulic connection direction (3) at the inlet (1) and at the outlet (2), as shown in the diagrams above and in the table below.

  • Page 36: Installation Of Dualquickfit Links

    NOTE Claws to be fixed on the frame return of the SPRING panels to keep the hydraulic hoses as close as possible to the frame are available in the DualSun inlet / outlet fittings kit.

  • Page 37: Heat Insulation And Protection Of Dualquickfit Connections

    DualQuickfit connections in EPDM are UV resistant In addition, the position of the DualQuickfit links, on the rear face of the DualSun Spring panels, protects them from direct exposure to UV rays 5.2. Hydraulic balancing of panel fields In the case of panel fields, the panel lines can be connected in parallel.
  • Page 38 Installation, use, maintenance manual DualSun SPRING WARNING It is recommended to install an automatic air vent fitted with a shut-off valve at each high point of the installation. It is recommended to close the shut-off valve of each air vent a few weeks after the hydraulic commissioning.
  • Page 39 Installation, use, maintenance manual DualSun SPRING Pressurized system Portrait panels - 2 lines / Single orientation / 1 column - DN15 or DN26 Portrait links Pressurized system Portrait panels - 2 lines / Double orientation / 1 column - DN15 or DN26...
  • Page 40 Installation, use, maintenance manual DualSun SPRING Pressurized system Portrait panels - 4 lines / Double orientation / 1 column - DN15 or DN26 Portrait links Pressurized system Portrait panels - 1 line / Single orientation / 2 columns - DN15 or DN26...
  • Page 41 Installation, use, maintenance manual DualSun SPRING Pressurized system Landscape panels - 2 lines / Single orientation / 1 column - DN15 Land- scape links Pressurized system Landscape panels - 2 lines / Double orientation / 1 column - DN15 Land-...
  • Page 42 Installation, use, maintenance manual DualSun SPRING Pressurized system Landscape panels - DN15 or DN26 Portrait links Pressurized system Portrait panels - DN15 Landscape links 3. Non-homogeneous lines When hydraulic balancing by Tichelmann loop is not feasible or the panel fields are not homogeneous, number of panels per field different and / or panels placed in different directions (portrait / landscape), the installation of balancing valves is recommended.
  • Page 43 Installation, use, maintenance manual DualSun SPRING IMPORTANT In the case of automatic balancing valves: Provide for the installation of bypass / isolation valves in parallel with the automatic balancing valves for commissioning filling (higher flow rate). In the case of manual balancing valves:...
  • Page 44 Installation, use, maintenance manual DualSun SPRING Pressurized system Landscape panels with balancing valves - DN15 or DN26 portrait links Pressurized system Portrait panels with bal- ancing valves - DN15 Landscape links...

  • Page 45: Hydraulic Balancing Of Panel Fields For Dualsun Solar Swimming Pool Heating System

    Installation, use, maintenance manual DualSun SPRING 5.2.2. Hydraulic balancing of panel fields for DualSun solar swimming pool heating system IMPORTANT The installation of isolation valves is necessary for: 1. Improve the bleeding of the air contained in the hydraulic circuit during filling while com-...
  • Page 46 Installation, use, maintenance manual DualSun SPRING Direct pool heating system 2 lines / 1 column - Portrait panels - DN26 Portrait links 1 line / 2 column direct pool heating system - Portrait panels - DN26 Portrait links 2. Non-homogeneous lines...

  • Page 47: Connection Of The Panel Field To The Transfer Circuit

    Selection of transfer lines - Pressurized system [47] Selection of transfer pipes for DualSun solar swimming pool heating system [49] 5.3.1.1. Selection of transfer lines - Pressurized system...
  • Page 48 • PEX-Al-PEX multilayer pipes It is possible to choose transfer pipes in multilayer PEX-Al-PEX due to the limited temperatures (<80 ° C) and pressures (<< 6 bar) in the solar circuit with DualSun SPRING hybrid solar panels. Note : • The hydraulic circuit must be designed taking into account the rate of thermal expansion of the pipes •...

  • Page 49: Insulation And Protection Of Piping

    For aesthetic reasons, it is possible to paint PVC pipes: take a good quality paint, anti UV if possible. 2. Selection of the diameter of the transfer pipes We have defined a chart to choose the diameter of the pipes according to the number of DualSun SPRING panels connected to the solar swimming pool heating system.
  • Page 50 In this case, the DualSun panel temperature probe is a 4 mm PT1000 probe, delivered with the DualSun essential kit. The probe is inserted into the notch provided in the heat exchanger of the SPRING panel, next to the hydraulic outlet connection.
  • Page 51 Installation, use, maintenance manual DualSun SPRING NOTE The probe must then be connected to the solar controller Refer to the instructions for the solar controller used.

  • Page 52: Cleaning The Surface Of The Modules

    Installation, use, maintenance manual DualSun SPRING 6. Cleaning the surface of the modules The greater the degree of contamination of the surface of the PV system, the less the cells are able to absorb the energy contained in the incident sunlight.

  • Page 53: Decommissioning Of The Installation

    Panel temperature probe [49] 7.2. Hydraulic disconnection For SPRING modules, once the installation has been emptied, the DualQuickfit quick couplings can be disman- tled using a special pliers, supplied in the essential kit. 7.3. Waste treatment When handling waste from a used DualSun system, the applicable regional and national regulations must be observed.

  • Page 54: Responsibilities

    For the other components of the installation, see the warranty conditions of the various manufacturers. 8.2. Disclaimer DualSun cannot be held liable in the following cases: • Failure to comply with the instructions contained in the Notice concerning the installation, use, operation and maintenance of the installation.

  • Page 55: Technical Appendices

    9. Technical appendices SPRING hydraulic pressure losses [55] SPRING thermal power [57] SPRING thermal behavior [60] Sizing and adjusting the DualSun filling vessel [64] 9.1. SPRING hydraulic pressure losses Hydraulic panel pressure loss in portrait or landscape / DualQuickfit DN15 Portrait connections...
  • Page 56 Installation, use, maintenance manual DualSun SPRING Panel hydraulic pressure loss in portrait or landscape / DualQuickfit DN15 Landscape connections Hydraulic head loss of panel in portrait / DualQuickfit DN26 Portrait connections...

  • Page 57: Spring Thermal Power

    EN 9806: 2017 certification tests for solar collectors without glazing carried out with a wind speed u = 1 m/s. The thermal power of DualSun SPRING panels with different wind speed values can be calculated according to the following coefficient formulas a0 and a1: •...
  • Page 58 Installation, use, maintenance manual DualSun SPRING Thermal power of DualSun SPRING panels with wind u = 1 m / s SPRING - NON-INSULATED SPRING - INSULATED...
  • Page 59 Installation, use, maintenance manual DualSun SPRING Thermal power output of DualSun SPRING panels with wind u = 3 m / s SPRING - NON-INSULATED SPRING - INSULATED...

  • Page 60: Spring Thermal Behavior

    Installation, use, maintenance manual DualSun SPRING 9.3. SPRING thermal behavior Temperature gradient provided by DualSun SPRING panels according to the inlet fluid temperature and the ambient air temperature: Calculation formula: DT = [2.G.A.a0/(2.⍴.Q.Cp+a1.A)]-[2.A.a1/(2.⍴.Q.Cp+a1.A)].(Tin-Ta) With: • DT = Tout - Tin = Heat input to the fluid by the solar panel [° C] •...
  • Page 61 Installation, use, maintenance manual DualSun SPRING Panel temperature gradient as a function of (Tin-Ta) for a flow rate of 60 L/h/panel SPRING - INSULATED Applications: ISWH / CSWH / Technical water storage Fluid: 40% glycol water (Cp = 3800 J/K/kg - ⍴ = 1000 kg/m...
  • Page 62 Installation, use, maintenance manual DualSun SPRING Panel temperature gradient as a function of (Tin-Ta) for a flow rate of 100 L/h/panel SPRING - NON-INSULATED Applications: Swimming pool heating - Pressurized / Heat pump Fluid: 40% glycol water (Cp = 3800 J/K/kg - ⍴ = 1000 kg/m...
  • Page 63 Installation, use, maintenance manual DualSun SPRING Panel temperature gradient as a function of (Tin-Ta) for a flow rate of 200 L/h/panel SPRING - NON-INSULATED Application: Heat pump Fluid: 40% glycol water (Cp = 3800 J/K/kg - ⍴ = 1000 kg/m...

  • Page 64: Sizing And Adjusting The Dualsun Filling Vessel

    Installation, use, maintenance manual DualSun SPRING 9.4. Sizing and adjusting the DualSun filling vessel The filling vessel is only recommended for installations of more than 12 DualSun SPRING hybrid panels in a pressurized system. The filling vessel makes it possible to store heat transfer fluid at the time of the hydraulic commissioning and to improve the quality of the filling of the installation.
  • Page 65 Installation, use, maintenance manual DualSun SPRING Heat transfer fluid expansion coefficient (%) Glycol con- Temperature (°C) tent (%)